U.S. patent number 9,787,017 [Application Number 15/073,060] was granted by the patent office on 2017-10-10 for electrical connector with two-piece cavity insert.
This patent grant is currently assigned to TE CONNECTIVITY CORPORATION. The grantee listed for this patent is TYCO ELECTRONICS CORPORATION. Invention is credited to Douglas John Hardy, David James Lane.
United States Patent |
9,787,017 |
Lane , et al. |
October 10, 2017 |
Electrical connector with two-piece cavity insert
Abstract
An electrical connector includes an outer contact and a cavity
insert. The outer contact has a mating segment, a terminating
segment, and a middle segment therebetween. The cavity insert
surrounds the middle segment of the outer contact. The cavity
insert is defined by an upper shell and a lower shell that couple
together at an interface. The upper shell extends along a portion
of a perimeter of the outer contact, and the lower shell extends
along a remaining portion of the perimeter of the outer contact.
The upper shell includes a first strap that extends across the
interface. The first strap includes a latching surface that engages
a corresponding first catch of the lower shell to couple the upper
shell to the lower shell.
Inventors: |
Lane; David James (Hummelstown,
PA), Hardy; Douglas John (Middletown, PA) |
Applicant: |
Name |
City |
State |
Country |
Type |
TYCO ELECTRONICS CORPORATION |
Berwyn |
PA |
US |
|
|
Assignee: |
TE CONNECTIVITY CORPORATION
(Berwyn, PA)
|
Family
ID: |
58398224 |
Appl.
No.: |
15/073,060 |
Filed: |
March 17, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01R
13/506 (20130101); H01R 13/426 (20130101); H01R
9/05 (20130101); H01R 9/0518 (20130101); H01R
24/40 (20130101); H01R 13/434 (20130101); H01R
2103/00 (20130101) |
Current International
Class: |
H01R
13/506 (20060101); H01R 24/40 (20110101); H01R
9/05 (20060101) |
Field of
Search: |
;439/578,585,465,731 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Other References
International Search Report, International Application No.
PCT/B2017/051494, International Filing Date Mar. 15, 2017. cited by
applicant.
|
Primary Examiner: Patel; Tulsidas C
Assistant Examiner: Chambers; Travis
Claims
What is claimed is:
1. An electrical connector comprising: an outer contact having a
mating segment, a terminating segment, and a middle segment
therebetween, the mating segment configured to engage a mating
contact of a mating connector, the terminating segment configured
to be electrically connected to a cable; and a cavity insert having
a front end and a rear end and defining a channel that receives the
outer contact therein, the cavity insert surrounding the middle
segment of the outer contact, the cavity insert defined by an upper
shell and a lower shell that couple together at an interface, the
first strap located at the front end of the cavity insert, the
second strap spaced apart from the first strap and located at the
rear end, the upper shell extending along a portion of a perimeter
of the outer contact, the lower shell extending along a remaining
portion of the perimeter of the outer contact, wherein the upper
shell has a curved body extending between a first edge and a second
edge, the upper shell including a first strap and a second strap
that extend beyond the first edge across the interface, the upper
shell further including a catch proximate to the second edge, the
first and second straps and the catch formed integral to the body
of the upper shell, wherein the lower shell has an identical shape
as the upper shell and is oriented 180 degrees relative to the
upper shell about a mating axis that is parallel to the channel,
wherein a latching surfaces of the first and second straps of the
upper shell engages the catch of the lower shell and a latching
surface of the first strap of a lower shell engages corresponding
first and second catches of a upper shell to couple a upper shell
to a lower shell.
2. The electrical connector of claim 1, wherein the curved body of
the upper shell extends between a first shoulder at the first edge
and a second shoulder at the second edge, the first and second
shoulders engaging corresponding shoulders of the lower shell at
the interface, the first strap of the upper shell disposed
proximate to the first shoulder and extending beyond the first
shoulder towards the lower shell.
3. The electrical connector of claim 1, wherein the curved body of
the lower shell extends between a first shoulder at the first edge
and a second shoulder at the second edge, the first and second
catches of the lower shell located proximate to the second shoulder
along a planar region of an outer surface of the body of the lower
shell, each of the first and second catches of the lower shell
including at least one of a hook surface of a tab that protrudes
outward from the outer surface relative to the channel or a wall of
a recess that extends inward from the outer surface relative to the
channel.
4. The electrical connector of claim 1, wherein the first strap of
the upper shell is cantilevered and extends to a free end, the
first strap including an inner side that faces the channel and an
opposite, outer side, the first strap defining an aperture
therethrough between the inner and outer sides, the latching
surface being a distal wall of the aperture proximate to the free
end of the first strap.
5. The electrical connector of claim 1, wherein the first strap of
the upper shell is cantilevered and extends from a fixed end to a
free end, the first strap including an inner side that faces the
channel, the first strap including a tab that protrudes from the
inner side of the first strap, the latching surface of the first
strap being a surface of the tab generally facing the fixed end of
the strap.
6. The electrical connector of claim 1, wherein the middle segment
of the outer contact includes a protrusion that extends radially
outward from the middle segment, the cavity insert defining an
indentation along an inner surface thereof that defines the
channel, the protrusion being received in the indentation when the
upper and lower shells are coupled together to secure the outer
contact within the cavity insert.
7. The electrical connector of claim 1, wherein the first and
second edges of the upper shell extend a length of the cavity
insert between a front end and a rear end thereof, the upper shell
including the first strap and a second strap protruding from the
first edge across the interface, the first and second straps spaced
apart along the length of the cavity insert, the catch of the upper
shell is defined by a first tab of multiple tabs extending from an
outer surface of the upper shell proximate to the second edge, the
tabs spaced apart along the length of the cavity insert, the tabs
of the upper shell including respective hook surfaces that engage
corresponding straps of the lower shell.
8. The electrical connector of claim 1, wherein the upper shell
lacks a strap extending from the second edge across the
interface.
9. An electrical connector comprising: an outer contact having a
mating segment, a terminating segment, and a middle segment
therebetween, the mating segment configured to engage a mating
contact of a mating connector, the terminating segment configured
to be electrically connected to a cable; and a cavity insert
defining a channel that receives the outer contact therein, the
cavity insert surrounding the middle segment of the outer contact,
the cavity insert defined by an upper shell and a lower shell that
couple together at an interface, the upper shell extending along a
portion of a perimeter of the outer contact, the lower shell
extending along a remaining portion of the perimeter of the outer
contact, the upper shell having a curved body extending between a
first edge and a second edge, the upper shell including a first
strap extending from the first edge towards the lower shell, the
first strap including a latching surface, the upper shell further
including a first tab extending from an outer surface of the upper
shell proximate to the second edge, the first tab located along a
planar region of the outer surface of the upper shell and
protruding radially outward from the planar region, the first tab
having a hook surface that defines a catch, the first strap and the
first catch tab formed integral to the body, wherein the lower
shell has an identical shape as the upper shell and is oriented 180
degrees relative to the upper shell about a mating axis that is
parallel to the channel; wherein the first edge of the upper shell
aligns with a second edge of the lower shell at the interface such
that hook surface of the latching surface of the first strap of the
upper shell engages a first tab of the lower shell, the second edge
of the upper shell aligning with a first edge of the lower shell at
the interface such that the first tab of the upper shell engages a
latching surface of a first strap of the lower shell.
10. The electrical connector of claim 9, wherein the upper and
lower shells each include a first shoulder at the respective first
edge and a second shoulder at the respective second edge, the first
shoulder of the upper shell engaging the second shoulder of the
lower shell and the second shoulder of the upper shell engaging the
first shoulder of the lower shell to define the interface.
11. The electrical connector of claim 9 as the upper and lower
shells are coupled together, the first strap of the lower shell is
configured to move along the planar region of the upper shell and
engage a ramp surface of the first tab of the upper shell, the ramp
surface deflecting the first strap radially outward until the
latching surface of the first strap clears the hook surface of the
tab and the first strap resiliently moves radially inward towards
the planar region.
12. The electrical connector of claim 9, wherein the first strap of
the upper shell is cantilevered and extends to a free end, the
first strap including an inner side that faces the channel and an
opposite, outer side, the first strap defining an aperture
therethrough between the inner and outer sides, the latching
surface being a distal wall of the aperture proximate to the free
end of the first strap.
13. The electrical connector of claim 9, wherein the cavity insert
has a front end and a rear end, the first strap of the upper shell
disposed proximate to the front end of the cavity insert, the upper
shell further including a second strap that is proximate to the
rear end of the cavity insert, the second strap extending across
the interface, the second strap including a latching surface that
engages a hook surface of a corresponding second tab of the lower
shell.
14. The electrical connector of claim 13, wherein the second strap
of the upper shell extends towards the lower shell from the first
edge of the upper shell, the upper shell lacking a strap extending
from the second edge thereof.
15. An electrical connector comprising: an outer housing having a
front end and defining a cavity that extends into the outer housing
from the front end, the cavity configured to removably receive a
mating connector therein along a mating axis; and a contact
assembly disposed within the cavity of the outer housing, the
contact assembly comprising: a center contact configured to engage
a first mating contact of the mating connector; a dielectric body
surrounding the center contact; an outer contact surrounding the
dielectric body, the outer contact extending between a mating
segment and a terminating segment, the mating segment configured to
engage a second mating contact of the mating connector, the
terminating segment configured to be electrically connected to a
cable; and a cavity insert having an inner surface surrounding and
engaging the outer contact, the cavity insert defined by an upper
shell and a lower shell that couple together at an interface, the
upper shell defining a portion of the inner surface of the cavity
insert, the lower shell defining a remaining portion of the inner
surface of the cavity insert, the upper shell having a curved body
extending between a first edge and a second edge, the lower shell
having a curved body extending between a first edge and a second
edge, the first edge of the upper shell aligning with the second
edge of the lower shell at the interface to define a first seam,
the second edge of the upper shell aligning with the first edge of
the lower shell at the interface to define a second seam, wherein
the upper shell includes a strap extending from the first edge
thereof across the first seam, the strap of the upper shell
including a latching surface that engages a catch of the lower
shell to couple the upper shell to the lower shell, the upper shell
lacking a strap extending from the second edge thereof, wherein the
strap of each of the upper and lower shells is cantilevered and
extends to a respective free end, each of the straps having an
inner side that faces the channel and an aperture through the strap
between the inner side and an opposite, outer side, the latching
surface of each of the straps being a distal wall of the aperture
proximate to the free end of the respective strap. wherein the
lower shell includes a strap extending from the first edge thereof
across the second seam, the strap of the lower shell including a
latching surface that engages a catch of the upper shell to couple
the lower shell to the upper shell, the lower shell lacking a strap
extending from the second edge thereof.
16. The electrical connector of claim 15, wherein the cavity insert
has a generally cylindrical shape and includes a flange extending
circumferentially along a perimeter of the cavity insert, the
flange engaging the outer housing within the cavity to secure an
axial position of the contact assembly relative to the outer
housing.
17. The electrical connector of claim 15, wherein the upper shell
has an identical shape as the lower shell, the lower shell oriented
180 degrees relative to the upper shell about the mating axis.
18. The electrical connector of claim 15, wherein the strap of the
upper shell is formed integral to the body of the upper shell and
the strap of the lower shell is formed integral to the body of the
lower shell.
19. The electrical connector of claim 15, wherein the outer contact
engages the portion of the inner surface of the cavity insert
defined by the upper shell and the portion of the inner surface of
the cavity defined by the lower shell to maintain the cavity insert
in a coupled state by blocking the upper shell and the lower shell
from sliding in opposite directions relative to one another
parallel to the interface.
Description
BACKGROUND OF THE INVENTION
The subject matter herein relates generally to connector
assemblies.
Radio frequency (RF) connector assemblies have been used for
numerous applications including military applications and
automotive applications, such as global positioning systems (GPS),
antennas, radios, mobile phones, multimedia devices, and the like.
The connector assemblies are typically coaxial cable connectors
that are provided at the end of coaxial cables.
In order to standardize various types of connector assemblies,
particularly the interfaces for such connector assemblies, certain
industry standards have been established. One of these standards is
referred to as FAKRA, which is an abbreviation for the German term
Fachnormenausschuss Kraftfahrzeugindustrie. FAKRA is the Automotive
Standards Committee in the German Institute for Standardization,
representing international standardization interests in the
automotive field. The FAKRA standard provides a system, based on
keying and color coding, for proper connector attachment. Specific
jack keys can only be connected to like plug keyways in FAKRA
connectors. Secure positioning and locking of connector housings is
facilitated by way of a FAKRA-defined catch on the housing of a
jack or first assembly and a cooperating latch on the housing of a
plug or second assembly.
The connector assemblies typically include a housing with a mating
interface for coupling to a mating connector. The housing holds a
contact assembly that electrically connects to corresponding mating
contacts of the mating connector. A cavity insert of the contact
assembly is typically used to secure the contact assembly within
the housing so the contact assembly does not become dislodged as
the mating connector is mated or unmated from the housing. The
cavity insert is an adapter that engages both an outer contact of
the contact assembly and an interior portion of the housing. The
cavity insert may allow the contact assembly to be compatible with
various different housings.
Typically, the cavity insert is cylindrical and is loaded over the
outer contact by sliding the cavity insert over an end of the outer
contact. For example, the cavity insert may be loaded over a rear
end of the outer contact which has a smaller diameter than a front
end of the outer contact. However, sliding the cavity insert over
an end of the outer contact may not be feasible or at least
desirable in some connectors. For example, some known outer
contacts are configured to electrically connect to relatively large
cables at the rear end of the outer contact, so the rear end of the
outer contact may be too large to be received within the cavity
insert. Due to spacing restrictions within the housing, it may not
be possible to enlarge the cavity insert in order to accommodate
the large rear end of the outer contact. Furthermore, some known
outer contacts are formed on carrier strips, and the contact
assembly may be assembled while the outer contact remains on the
carrier strip. Even if the rear end of the outer contact is small
enough to be received within the cavity insert, the rear end may be
secured to the carrier strip which blocks the ability of the cavity
insert to be loaded over the rear end. A need remains for an
electrical connector that is able to accommodate various outer
contacts therein while adhering to the space restrictions within
the housing and any applicable industry standard
specifications.
BRIEF DESCRIPTION OF THE INVENTION
In one embodiment, an electrical connector is provided that
includes an outer contact and a cavity insert. The outer contact
has a mating segment, a terminating segment, and a middle segment
therebetween. The mating segment is configured to engage a mating
contact of a mating connector. The terminating segment is
configured to be electrically connected to a cable. The cavity
insert defines a channel that receives the outer contact therein.
The cavity insert surrounds the middle segment of the outer
contact. The cavity insert is defined by an upper shell and a lower
shell that couple together at an interface. The upper shell extends
along a portion of a perimeter of the outer contact, and the lower
shell extends along a remaining portion of the perimeter of the
outer contact. The upper shell includes a first strap that extends
across the interface. The first strap includes a latching surface
that engages a corresponding first catch of the lower shell to
couple the upper shell to the lower shell.
In another embodiment, an electrical connector is provided that
includes an outer contact and a cavity insert. The outer contact
has a mating segment, a terminating segment, and a middle segment
therebetween. The mating segment is configured to engage a mating
contact of a mating connector. The terminating segment is
configured to be electrically connected to a cable. The cavity
insert defines a channel that receives the outer contact therein.
The cavity insert surrounds the middle segment of the outer
contact. The cavity insert is defined by an upper shell and a lower
shell that couple together at an interface. The upper shell extends
along a portion of a perimeter of the outer contact, and the lower
shell extends along a remaining portion of the perimeter of the
outer contact. The upper shell has a curved body extending between
a first edge and a second edge. The upper shell includes a first
strap extending from the first edge towards the lower shell. The
first strap includes a latching surface. The upper shell further
includes a first catch extending from an outer surface of the upper
shell proximate to the second edge. The lower shell has an
identical shape as the upper shell and is oriented 180 degrees
relative to the upper shell about a mating axis that is parallel to
the channel. The first edge of the upper shell aligns with a second
edge of the lower shell such that the latching surface of the first
strap of the upper shell engages a first catch of the lower shell.
The second edge of the upper shell aligns with a first edge of the
lower shell such that the first catch of the upper shell engages a
latching surface of a first strap of the lower shell.
In another embodiment, an electrical connector is provided that
includes an outer housing and a contact assembly. The outer housing
has a front end and defines a cavity that extends into the outer
housing from the front end. The cavity is configured to receive a
mating connector therein along a mating axis. The contact assembly
is disposed within the cavity of the outer housing. The contact
assembly includes a center contact, a dielectric body, an outer
contact, and a cavity insert. The center contact is configured to
engage a first mating contact of the mating connector. The
dielectric body surrounds the center contact. The outer contact
surrounds the dielectric body. The outer contact extends between a
mating segment and a terminating segment. The mating segment is
configured to engage a second mating contact of the mating
connector. The terminating segment is configured to be electrically
connected to a cable. The cavity insert surrounds the outer
contact. The cavity insert is defined by an upper shell and a lower
shell that couple together at an interface. The upper shell extends
along a portion of a perimeter of the outer contact, and the lower
shell extends along a remaining portion of the perimeter of the
outer contact. The upper shell includes a first strap that extends
across the interface. The first strap includes a latching surface
that engages a corresponding first catch of the lower shell to
couple the upper shell to the lower shell.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a connector system formed in accordance with an
exemplary embodiment.
FIG. 2 is an exploded view of a female connector and a cable of the
connector system according to an embodiment.
FIG. 3 is a perspective exploded view of a contact assembly of the
female connector according to an embodiment.
FIG. 4 is a side perspective view of the contact assembly in an
assembled state according to an embodiment.
FIG. 5 is an exploded cross-sectional view of a cavity insert of
the female connector taken along line 5-5 shown in FIG. 2.
FIG. 6 is an assembled cross-sectional view of the cavity insert
and an outer contact taken along the line 5-5.
FIG. 7 is a cross-sectional view of a portion of the assembled
cavity insert according to an alternative embodiment.
DETAILED DESCRIPTION OF THE INVENTION
One or more embodiments described herein disclose a connector
system that includes a first connector and a second connector. At
least one of the first connector or the second connector includes
an outer contact and a cavity insert that surrounds the outer
contact. The cavity insert extends between the outer contact and an
outer housing of the connector to hold the outer contact (and any
components within and/or coupled to the outer contact) in a secured
position relative to the outer housing. The cavity insert has a
two-piece construction that is formed of two shells that couple
together to define the cavity insert. The two shells are moved
towards each other to be coupled together with the outer contact
between the two shells. Thus, the cavity insert is not loaded
axially over an end of the outer contact in order to surround the
outer contact.
The two shells are coupled to one another by a latching mechanism.
The latching mechanism includes at least one strap that extends
from one of the shells towards the other shell and a catch on the
other shell that engages a latching surface on the strap. The
latching mechanism may include multiple straps and corresponding
catches. Optionally, each shell may be hermaphroditic, including
both at least one catch and at least one latching strap. In an
embodiment, the latching components (e.g., the latching straps and
catches) of each shell are integrally formed on the respective
shell, such as during a molding process. Furthermore, the two
shells may have an identical shape as one another, such that the
same mold or process may be used to make both shells that couple to
form the cavity insert.
As used herein, the term "surrounding" means extending around a
periphery of another object in at least one dimension, such as
encircling the object along a segment of the length of the object.
The term "surrounding" as used herein does not necessarily require
that the surrounded object be completely enclosed or encased by the
surrounding object in all dimensions.
FIG. 1 illustrates a connector system 100 formed in accordance with
an exemplary embodiment. The connector system 100 includes a first
electrical connector 102 and a second electrical connector 104 that
are configured to be mated together to transmit electrical signals
therebetween. In the illustrated embodiment, the first electrical
connector 102 is a male connector, and the second electrical
connector 104 is a female connector, such that a portion of the
first electrical connector 102 is received within a cavity 106 of
the second electrical connector 104 during a mating operation. More
specifically, a male housing 108 (e.g., a nose cone) of the first
connector 102 is received within the cavity 106 defined by a female
housing 110 of the female connector 104. Although shown as un-mated
in FIG. 1, the first and second connectors 102, 104 are poised for
mating along a mating axis 112. As used herein, the first
electrical connector 102 is referred to as male connector 102 or
mating connector 102, and the second electrical connector 104 is
referred to as female connector 104 or simply as connector 104.
The connector system 100 may be used in numerous applications
across various industries, such as the automotive industry, the
home appliance industry, the aviation industry, and the like, to
electrically couple two or more devices and/or electrical
components. For example, in the automotive industry, the electrical
connectors 102, 104 may be used for radio frequency communications,
such as to electrically connect an antenna to a controller and/or
processing device.
The male connector 102 and the female connector 104 each
electrically connect to different electrical components and provide
a conductive pathway between the corresponding electrical
components. In the illustrated embodiment, the male connector 102
and the female connector 104 are electrically connected to
corresponding conductive cables or wires 114, 116, such as coaxial
cables. In an alternative embodiment, the male connector 102 and/or
the female connector 104 may be mounted (e.g., edge-mounted) to a
corresponding circuit board. The cable 114 is electrically
terminated (e.g., crimped, soldered, etc.) to electrical contacts
of the male connector 102. The cable 116 is electrically terminated
to electrical contacts of the female connector 104. The electrical
contacts of the male connector 102 engage the electrical contacts
of the female connector 104 when the connectors 102, 104 are mated.
Various electrical signals conveying power, control messages, data,
or the like, may be transmitted through the connectors 102, 104
between the cable 114 and the cable 116.
The male connector 102 and the female connector 104 both have
in-line shapes in the illustrated embodiment. For example, the
mating axis 112 along which the male connector 102 is loaded into
the cavity 106 is generally parallel to the orientations of the
cable 114 exiting the male connector 102 and the cable 116 exiting
the female connector 104. In an alternative embodiment, the male
connector 102 and/or the female connector 104 may have a right
angle shape.
In the illustrated embodiment, the male connector 102 and the
female connector 104 constitute FAKRA connectors which are RF
connectors that have an interface that complies with the standard
for a uniform connector system established by the FAKRA automobile
expert group. The FAKRA connectors have a standardized keying
system and locking system that fulfill the high functional and
safety requirements of automotive applications. The FAKRA
connectors are based on a subminiature version B connector (SMB
connector) that feature snap-on coupling and are designed to
operate at specific impedances, such as 50, 75, 93, and/or 125
Ohms. The connector system 100 may utilize other types of
connectors other than the FAKRA connectors described herein.
During mating, a front end 126 of the male connector 102 is moved
along the mating axis 112 and is plugged into the cavity 106 of the
female connector 104 through a front end 128 thereof. As used
herein, relative or spatial terms such as "front," "rear," "top,"
or "bottom" are only used to distinguish the referenced elements
and do not necessarily require particular positions or orientations
relative to the surrounding environment of the connector system
100. The male connector 102 has one or more keying features 118,
and the female connector 104 has one or more keying features 120
that complement the keying features 118 of the male connector 102.
In the illustrated embodiment, the keying features 118 are ribs and
the keying features 120 are channels that receive the ribs 118. Any
number of keying features 118, 120 may be provided. The keying
features 118, 120 may be part of the standardized design of the
FAKRA connector. For example, the keying ribs 118 and the keying
channels 120 may be configured to restrict the mate-ability of each
of the connectors 102, 104 to one or more specific mating
connectors.
The male connector 102 has a latching feature 122 that is
configured to engage a complementary latching feature 124 of the
female connector 104 to retain a mating connection between the two
connectors 102, 104 (by restricting undesired un-mating of the
connectors 102, 104). In the illustrated embodiment, the latching
feature 122 is a catch, and the latching feature 124 is a
deflectable latch that engages the catch 122 when the connectors
102, 104 are mated together. The latch 124 is configured to be
lifted or pivoted over the catch 122 in order to disconnect the
male and female connectors 102, 104.
FIG. 2 is an exploded view of the female connector 104 and the
cable 116 according to an embodiment. The female connector 104
includes the female housing 110 (also referred to herein as outer
housing 110) and a contact assembly 130. The contact assembly 130
is held within the outer housing 110. The contact assembly 130
includes a center contact 132, a dielectric body 134, an outer
contact 136, a cavity insert 138, and an optional ferrule 140. In
other embodiments, the female connector 104 may include one or more
additional components and/or may not include all of the listed
components.
The cable 116 may be a coaxial cable that has a center conductor
170 (for example, one or more wires) surrounded by a dielectric
layer 172. A cable braid 174 surrounds the dielectric layer 172.
The cable braid 174 provides shielding for the center conductor 170
along the length of the cable 116. A cable jacket 176 surrounds the
cable braid 174 and provides protection for the cable braid 174,
the dielectric layer 172, and the center conductor 170 from
external forces and contaminants. The cable 116 is configured to be
electrically connected to the contact assembly 130 via crimping,
soldering, or the like.
In the illustrated embodiment, the center contact 132 of the
contact assembly 130 constitutes a socket contact that is
configured to receive and electrically engage a pin contact of the
male connector 102 (shown in FIG. 1). Alternatively, the center
contact 132 may be a pin contact or another type of contact. The
center contact 132 is composed of a conductive material such as one
or more metals. The center contact 132 is terminated to the center
conductor 170 of the cable 116, such as via crimping.
The dielectric body 134 surrounds the center contact 132. For
example, the dielectric body 134 defines a passage 142 that
receives the center contact 132 therein. The dielectric body 134 is
composed of a dielectric material, such as one or more plastics.
The dielectric body 134 is configured to extend between the center
contact 132 and the outer contact 136 to electrically insulate the
two contacts 132, 136 from each other.
The outer contact 136 surrounds the dielectric body 134 and the
center contact 132 that is within the dielectric body 134. The
outer contact 136 is composed of a conductive material such as one
or more metals. The outer contact 136 provides shielding for the
center contact 132, such as from electromagnetic or radio frequency
interference. The outer contact 136 is configured to be
electrically connected to the cable braid 174 of the cable 116.
The outer contact 136 extends between a front end 144 and a rear
end 146, and defines a chamber 148 that extends through the outer
contact 136 between the front and rear ends 144, 146. The
dielectric body 134 is received in the chamber 148, and the cable
116 that is terminated to the center contact 132 protrudes from the
rear end 146 of the outer contact 136. The outer contact 136 has a
generally cylindrical or barrel shape. In an embodiment, the outer
contact 136 is stamped and formed into the cylindrical shape by
stamping and then rolling a panel of sheet metal.
The outer contact 136 includes a mating segment 150 that extends
rearward from the front end 144 and a terminating segment 152 that
extends frontward from the rear end 146. The mating segment 150 is
configured to engage an outer mating contact (not shown) of a
mating connector, such as the male connector 102 (shown in FIG. 1).
The mating segment 150 may include one or more retention features
154, such as deflectable beams, bumps, barbs, or the like in order
to maintain engagement between the mating segment 150 of the outer
contact 136 and the outer mating contact. The terminating segment
152 is configured to be electrically connected to the cable braid
174 of the cable 116. For example, the cable braid 174 may surround
the terminating segment 152 and may be crimped to the terminating
segment 152 via the ferrule 140. Optionally, the outer contact 136
may include a middle segment 156 between the mating segment 150 and
the terminating segment 152 along the length of the outer contact
136. The middle segment 156 may have a different diameter than at
least one of the mating segment 150 and the terminating segment
152. For example, in the illustrated embodiment, the middle segment
156 has a smaller diameter than the mating segment 150 and a larger
diameter than the terminating segment 152. The outer contact 136 is
stepped along the length to define at least a first step 158 and a
second step 160. The first step 158 separates the mating segment
150 from the middle segment 156. The second step 160 separates the
middle segment 156 from the terminating segment 152. In an
alternative embodiment, the terminating segment 152 may have a
larger diameter than the middle segment 150, such as if the
terminating segment 152 is configured to electrically connect to a
cable that is larger than the cable 116.
The cavity insert 138 surrounds at least a portion of the outer
contact 136. The cavity insert 138 extends between a front end 162
and a rear end 164 and defines a channel 166 that extends through
the cavity insert 138 between the front and rear ends 162, 164. The
outer contact 136 is held within the channel 166. In an embodiment,
the outer contact 136 surrounds the middle segment 156 of the outer
contact 136, such that an inner surface 168 of the cavity insert
138 engages the middle segment 156. The cavity insert 138
optionally may surround at least a portion of the mating segment
150 and/or the terminating segment 152. The inner surface 168 of
the cavity insert 138 may engage the first step 158 and/or the
second step 160. The cavity insert 138 is configured to secure the
outer contact 136 axially within the channel 166, such that the
outer contact 136 does not move axially relative to the cavity
insert 138. Optionally, the cavity insert 138 does not allow the
outer contact 136 to rotate relative to cavity insert 138. The
cavity insert 138 is an adapter that is configured to engage the
outer housing 110 to hold the contact assembly 130 in a fixed axial
position within the cavity 106 of the housing 110. For example, the
cavity insert 138 may include at least one flange 186 that extends
circumferentially along a perimeter of the cavity insert 138. The
flange 186 is configured to engage the outer housing 110 within the
cavity 106 in order to secure the axial position of the contact
assembly 130.
The ferrule 140 is configured to be crimped over the cable 116 to
the terminating segment 152 of the outer contact 136. The ferrule
140 provides electrical termination of the braid 174 to the outer
contact 136 and strain relief for the cable 116. In an exemplary
embodiment, the ferrule 140 is configured to be crimped to both the
cable braid 174 and the cable jacket 176 of the cable 116.
The female outer housing 110 extends between the front end 128 and
a rear end 129. The outer housing 110 has a generally box shaped
outer profile. The cavity 106 of the outer housing 110 may be a
generally cylindrical bore extending through the outer housing 110.
The cavity 106 may have steps, shoulders and/or channels formed
therein for engaging and securing the cavity insert 138
therein.
In an embodiment, the outer housing 110 is configured to receive a
retainer clip 182 that extends through an opening in a side wall
184 of the housing 110. The retainer clip 182 is configured to be
loaded into the housing 110 subsequent to the contact assembly 130
in order to secure the contact assembly 130 to the housing 110. For
example, the retainer clip 182 may engage one or more flanges 186
of the cavity insert 138 to secure the axial position of the
contact assembly 130 within the cavity 106.
Although the female connector 104 is shown and described in FIG. 2,
the male connector 102 (shown in FIG. 1) may have similar and/or
identical components as the components of the female connector 104.
For example, the male connector 102 may include a contact assembly
that is received within the male housing 108 (shown in FIG. 1). The
contact assembly of the male connector 102 may include a center
contact, a dielectric body, an outer contact, and a cavity insert
that are at least similar to the components of the contact assembly
130 described in FIG. 2. For example, the male connector 102 may
include a cavity insert that is similar to the cavity insert 138 of
the female connector 104 shown and described below.
In an embodiment, the cavity insert 138 is formed of a two-piece
construction, including a first shell 188 and a second shell 190.
The first and second shells 188, 190 are separate, discrete parts
that couple together to define the cavity insert 138. For example,
the first shell 188 extends along a portion of the perimeter of the
outer contact 136, and the second shell 190 extends along a
remaining portion of the perimeter of the outer contact 136. The
first and second shells 188, 190 engage one another at an interface
194 to form the assembled and intact cavity insert 138 that is
shown in FIG. 2.
FIG. 3 is a perspective exploded view of the contact assembly 130
of the female connector 104 according to an embodiment. The center
contact 132 (shown in FIG. 2) within the dielectric body 134 is not
visible in the illustrated embodiment. The contact assembly 130 is
oriented with respect to a vertical or elevation axis 191, a
lateral axis 193, and the mating axis 112. The axes 191, 193, 112
are mutually perpendicular. Although the elevation axis 191 appears
to extend in a generally parallel to gravity, it is understood that
the axes 191, 193, 112 are not required to have any particular
orientation with respect to gravity. In FIG. 3, the first shell 188
extends above the outer contact 136 (along the vertical axis 191),
and the second shell 190 is disposed below the outer contact 136.
As used herein, the first shell 188 is referred to as an upper
shell 188 and the second shell 190 is referred to as a lower shell
190. As stated above, the terms "upper" and "lower" are only used
to distinguish the referenced elements and do not necessarily
require particular positions or orientations relative to the
surrounding environment of the female connector 104. Thus, the
upper shell 188 may be below the lower shell 190 if the contact
assembly 130 is rotated 180 degrees.
Optionally, the outer contact 136 is connected to a metal carrier
strip 196 when the cavity insert 138 is assembled around the outer
contact 136. The terminating segment 152 of the outer contact 136
is mechanically connected to the carrier strip 196. Since the
carrier strip 196 is connected to the terminating segment 152, a
pre-assembled cavity insert 138 is not able to be received over the
terminating segment 152 to surround the outer contact 136. The
channel 166 (shown in FIG. 2) of the cavity insert 138 may be
smaller in diameter than the mating segment 150, such that the
cavity insert 138 also cannot be loaded over the mating segment
150. Thus, a pre-assembled cavity insert 138 would not be able to
surround the outer contact 136. In the illustrated embodiment,
since the cavity insert 138 has a two-piece construction, the
cavity insert 138 may be assembled around the outer contact 136.
For example, the cavity insert 138 is assembled in-situ around the
outer contact 136 such that the outer contact 136 is disposed
between the two shells 188, 190 as the two shells 188, 190 are
coupled together.
Optionally, the upper and lower shells 188, 190 may each be
connected to respective plastic carrier strips 198. The carrier
strips 198 include links 200 that extend outward from the
respective shells 188, 190 along the lateral axis 193. The links
200 may be severed from the shells 188, 190 prior to or after the
shells 188, 190 are coupled to each other to surround the outer
contact 136. In an embodiment, the shells 188, 190 are each
composed of a dielectric material, such as one or more plastics.
The shells 188, 190 may be formed by a molding process. The carrier
strips 198 may be formed with the respective shells 188, 190 during
the same molding process. In an embodiment, the upper shell 188 has
a unitary, one-piece body 202, and the lower shell 190 has a
unitary one-piece body 204. Thus, the latching features on the
upper and lower shells 188, 190 that are used to couple the shells
188, 190 to each other may be formed integral to the respective
bodies 202, 204 of the shells 188, 190. Alternatively, one or more
latching features or other components may be attached to a
corresponding shell 188, 190 after forming the shell 188, 190, such
as via bonding, an adhesive, a fastener, or the like.
The body 202 of the upper shell 188 is curved between a first edge
206 and a second edge 208. The first edge 206 is laterally spaced
apart from the second edge 208. The upper shell 188 extends
longitudinally along the mating axis 112 between a front end 210
and a rear end 212. The first and second edges 206, 208 extend the
length of the upper shell 188 between the front and rear ends 210,
212. The curved body 202 includes an inner surface 214 and an outer
surface 216. The inner surface 214 defines a portion of the channel
166 (shown in FIG. 2) when the cavity insert 138 is assembled. The
outer surface 216 defines a portion of an outer perimeter of the
assembled cavity insert 138. The body 202 of the upper shell 188 in
an embodiment defines approximately half of the outer perimeter of
the assembled cavity insert 138, but may define more or less than
half of the outer perimeter of the cavity insert 138 in other
embodiments. In the orientation shown in FIG. 3, the body 202 has a
convex curve relative to the links 200 that extend from the body
202, such that the body 202 arches upward from the edges 206,
208.
The upper shell 188 includes latching components used to couple the
upper shell 188 to the lower shell 190. For example, the upper
shell 188 in the illustrated embodiment includes a strap 218 that
extends beyond the first edge 206 of the upper shell 188 towards
the lower shell 190. The strap 218 extends generally vertically
downward from the first edge 206. The strap 218 includes a latching
surface 220 that is configured to engage a corresponding catch 284
of the lower shell 190 to couple the upper shell 188 to the lower
shell 190. The upper shell 188 also includes multiple catches 222
that are spaced apart along the length of the upper shell 188. The
catches 222 are each configured to engage a latching surface 250 of
corresponding straps 248 of the lower shell 190. In the illustrated
embodiment, the upper shell 188 includes three catches 222,
including a first catch 222A proximate to the front end 210, a
second catch 222B proximate to the rear end 212, and a third catch
222C disposed axially between the first and second catches 222A,
222B. The three catches 222A-C are all disposed along the outer
surface 216 proximate to the second edge 208 of the upper shell
188. The upper shell 188 may include other than three catches 222
proximate to the second edge 208 in an alternative embodiment.
In the illustrated embodiment, the catches 222 of the upper shell
188 are defined by hook surfaces of respective tabs 224 that
protrude radially outward from the outer surface 216. The tabs 224
may align with corresponding flange segments 226 that define
portions of the flanges 186 (shown in FIG. 2) of the assembled
cavity insert 138. The outer surface 216 of the upper shell 188 may
include one or more planar regions 228 proximate to the second edge
208. The outer surface 216 along the planar regions 228 is flat or
planar, as opposed to being curved. The catches 222 are disposed
along the planar regions 228. For example, the tabs 224 protrude
radially outward from the planar regions 228 of the outer surface
216.
The body 204 of the lower shell 190 is curved between a first edge
236 and a second edge 238 that are spaced apart laterally relative
to one another. The lower shell 190 extends longitudinally along
the mating axis 112 between a front end 240 and a rear end 242. The
first and second edges 236, 238 extend the length of the lower
shell 190 between the front and rear ends 240, 242. The curved body
204 includes an inner surface 244 and an outer surface 246. The
inner surface 244 defines a portion of the channel 166 (shown in
FIG. 2), and the inner surface 214 of the upper shell 188 defines a
remaining portion of the channel 166 when the cavity insert 138 is
assembled. The outer surface 246 defines a portion of the outer
perimeter of the assembled cavity insert 138, such that the outer
surfaces 216, 246 of the upper and lower shells 188, 190 define an
entirety of the outer perimeter of the cavity insert 138. In the
orientation shown in FIG. 3, the body 204 has a concave curve
relative to the links 200 that extend from the body 204, such that
the body 204 arches downward from the edges 236, 238.
The lower shell 190 includes latching components used to couple the
lower shell 190 to the upper shell 188. For example, the lower
shell 190 in the illustrated embodiment includes multiple straps
248 that extends beyond the first edge 236 of the lower shell 190
towards the upper shell 188. The straps 248 extend generally
vertically upward from the first edge 236. The straps 248 each
include a latching surface 250 that is configured to engage a
corresponding catch 222 of the upper shell 188 to couple the upper
and lower shells 188, 190. In the illustrated embodiment, the lower
shell 190 includes three straps 248, including a first strap 248A
proximate to the front end 240, a second strap 248B proximate to
the rear end 242, and a third strap 248C disposed axially between
the first and second straps 248A, 248B. The latching surfaces 250
of the first, second, and third straps 248A-C align with and engage
the first, second, and third catches 222A-C of the upper shell 188,
respectively, when the shells 188, 190 are coupled. The three
straps 248A-C of the lower shell 190 are all disposed along (and
extend from) the first edge 236 of the lower shell 190. The lower
shell 190 may include other than three total straps 248 and/or
other than three straps 248 along the first edge 236 in an
alternative embodiment.
The straps 248A-C may have the same or similar sizes and shapes as
one another. Each strap 248 is a cantilevered beam or limb that
protrudes beyond or from the first edge 236 to a respective free
end 252. The straps 248 are at least semi-rigid, such that the
straps 248 are able to deflect and resiliently return towards an
initial, resting position when a deflecting force on the strap 248
is removed. Each strap 248 includes an inner side 254 that faces
the channel 166 (shown in FIG. 2) and an opposite outer side 256
that faces outward away from the channel 166. The inner side 254
may be approximately planar, and the outer side 256 may be curved.
In an embodiment, the straps 248 each define an aperture 258 that
extends through the respective strap 248 between the inner and
outer sides 254, 256. The aperture 258 is defined along a portion
of the strap 248 that extends beyond the first edge 236. The
latching surface 250 is a distal wall of the aperture 258. The
distal wall 250 is proximate to the free end 252 of the respective
strap 248. The distal wall 250 may face generally vertically
downward and/or towards the first edge 236 from which the strap 248
extends. In an alternative embodiment, the aperture 258 does not
extend fully through the respective strap 248, but rather is a
recess or indentation defined along the inner side 254 of the strap
248. The latching surface 250 in such alternative embodiment may be
a distal wall of the recess.
Although not shown in FIG. 3, in an embodiment the lower shell 190
includes at least one catch 284 (shown in FIG. 4) that extends from
the outer surface 246 proximate to the second edge 238. The catch
284 may be similar in shape, size, and/or features to the catches
222 of the upper shell 188. In addition, although only partially
visible in FIG. 3, the strap 218 of the upper shell 188 optionally
may be substantially similar in shape, size, and/or features to the
straps 248 of the lower shell 190. In an embodiment, both the upper
shell 188 and the lower shell 190 are hermaphroditic such that each
shell 188, 190 includes at least one catch and at least one strap
that includes a latching surface. In an alternative embodiment, the
shells 188, 190 are not hermaphroditic such that the upper shell
188 includes only straps 218 or only catches 222, and the lower
shell 190 includes only the complementary latching features, such
as only multiple catches 284 or only multiple straps 248.
As shown in FIG. 3, the straps 218, 248 of the upper and lower
shells 188, 190, respectively, are disposed along the respective
first edges 206, 236 of the shells 188, 190. The straps 218, 248
are not located along the respective second edges 208, 238.
Furthermore, the respective catches 222, 284 (shown in FIG. 4) are
disposed proximate to the second edges 208, 238, of the shells 188,
190, but not proximate to the first edges 206, 236. In one or more
alternative embodiments, however, the upper shell 188 may include
at least one strap 218 disposed along each of the first and second
edges 206, 208 and/or at least one catch 222 proximate to each of
the first and second edges 206, 208. Similarly, in an alternative
embodiment the lower shell 190 may include at least one strap 248
disposed along each of the first and second edges 236, 238 and/or
at least one catch 284 proximate to each of the first and second
edges 236, 238.
In an embodiment, the upper shell 188 and the lower shell 190 have
identical shapes. For example, the size, contour, and features of
the upper shell 188 are identical to the size, contour, and
features of the lower shell 190. The upper and lower shells 188,
190 may be formed via the same process, such as by being formed in
the same or an identical mold. Thus, both the upper and lower
shells 188, 190 are able to be produced using only a single mold,
which may reduce manufacturing costs. In the illustrated
embodiment, the lower shell 190 is oriented 180 degrees relative to
the upper shell 188 about the mating axis 112. For example, since
the upper shell 188 is identical to the lower shell 190, the strap
218 of the upper shell 188 that is visible in FIG. 3 is the same as
the first strap 248A of the lower shell 190. The use of the term
"identical" herein recognizes that the one or both shells 188, 190
may have imperfections, blemishes, and other de minimis
irregularities that are not shared by both shells 188, 190 (for
example, resulting from the manufacturing process or subsequent
handling).
As shown in FIG. 3, the outer contact 136 may include a protrusion
260 that extends radially outward from the middle segment 156 of
the outer contact 136. The lower shell 190 defines an indentation
262 along the inner surface 244. The indentation 262 receives the
protrusion 260 therein when the upper and lower shells 188, 190 are
coupled to secure the outer contact 136 within the cavity insert
138. As shown in FIG. 3, the lower shell 190 defines two
indentations 262, with one indentation 262 proximate to the first
edge 236 and the other indentation 262 proximate to the second edge
238. Based on the orientations of the outer contact 136 and the
lower shell 190 in the illustrated embodiment, the protrusion 260
is received within the indentation 262 proximate to the first edge
236, and another protrusion (not shown) of the middle segment 156
may be received in the other indentation 262 proximate to the
second edge 238. The receipt of the protrusion 260 in the
corresponding indentation 262 may axially and rotationally lock or
secure the outer contact 136 relative to the cavity insert 138.
Although not shown, the upper shell 188 may define one or more
indentations that interface with the indentations 262 to define
larger recesses. In an alternative embodiment, the mating segment
156 may define a depression and the cavity insert 138 may include a
protrusion that is configured to extend into the depression. The
cavity insert 138 may additionally secure the axial position of the
outer contact 136 via engagement with the first step 158 and/or the
second step 160 of the outer contact 136 or one or more other parts
of the outer contact 136.
FIG. 4 is a side perspective view of the contact assembly 130 in an
assembled state according to an embodiment. The cavity insert 138
is whole in FIG. 4 such that the upper shell 188 is coupled to the
lower shell 190 to surround the outer contact 136. The illustrated
embodiment of the cavity insert 138 differs slightly from the
embodiment shown in FIG. 3 because the cavity insert 138 only
includes two latching features instead of three along the length of
the cavity insert 138. The cavity insert 138 extends between a
front end 264 and a rear end 266. The front end 264 is defined by
the front end 210 of the upper shell 188 and the front end 240 of
the lower shell 190. The rear end 266 is defined by the respective
rear ends 212, 242 of the upper and lower shells 188, 190. In the
illustrated embodiment, the upper shell 188 includes a first strap
218A proximate to the front end 264 of the cavity insert 138 and a
second strap 218B proximate to the rear end 266. The second strap
218B is identical or as similar to the first strap 218A. The straps
218A, 218B both extend across the interface 194 defined between the
shells 188, 190 to engage corresponding catches 284A, 284B of the
lower shell 190. The interface 194 between the shells 188, 190
defines a first seam 268 between the first edge 206 of the upper
shell 188 and the second edge 238 of the lower shell 190. The first
seam 268 extends the length of the cavity insert 138. The straps
218A, 218B extend across the first seam 268. The straps 218A, 218B
overlap portions of the outer surface 246 of the lower shell 190
proximate to the catches 284A, 284B. Although not visible in FIG.
4, the interface 194 also defines a second seam 270 (shown in FIG.
6) that extends the length of the cavity insert 138 between the
second edge 208 of the upper shell 188 and the first edge 236 of
the lower shell 190.
FIG. 5 is an exploded cross-sectional view of the cavity insert 138
taken along line 5-5 shown in FIG. 2. The upper shell 188 is poised
for coupling to the lower shell 190. In the illustrated embodiment,
the curved body 202 of the upper shell 188 includes a first
shoulder 272 at the first edge 206 and a second shoulder 274 at the
second edge 208. The shoulders 272, 274 are generally planar
surfaces that extend inward from the respective edges 206, 208. The
strap 218 of the upper shell 188 is disposed proximate to the first
shoulder 272 and extends beyond the first shoulder 272. In the
illustrated embodiment, the strap 218 is disposed outward of the
shoulder 272 such that the shoulder 272 extends inward from the
edge 206 and the strap 218 extends outward from the edge 206. The
catch 222 of the upper shell 188 is disposed along the planar
region 228 of the outer surface 216 proximate to the second
shoulder 274.
The strap 218 extends from a fixed end 276 at the body 202 to a
free end 302. The fixed end 276 may be at the first edge 206 or may
be spaced apart from the first edge 206 along a perimeter of the
outer surface 216 of the upper shell 188. The strap 218 defines an
aperture 278 that extends through the strap 218. The aperture 278
is similar to the aperture 258 that extends through the strap 248
of the lower shell 190. The aperture 278 may be defined between a
tip segment 280 of the strap 218 and the first edge 206. The tip
segment 280 includes the free end 302. The tip segment 280 also
includes the latching surface 220. For example, the latching
surface 220 may be a distal wall of the aperture 278.
The catch 222 of the upper shell 188 is a hook surface of the tab
224 that protrudes outward from the outer surface 216. In an
embodiment, the hook surface 222 may have an acute angle relative
to the planar region 228 above the tab 224. For example, the hook
surface 222 is angled to extend at least slightly away from the
edge 208 along the vertical axis 191. In an alternative embodiment,
the hook surface 222 may extend perpendicular to the planar region
228. In the illustrated embodiment, the tab 224 includes a ramp
surface 282 that slopes outward away from the planar region 228 of
the outer surface 216 as the distance from the second edge 208
increases. The ramp surface 282 extends from the second edge 208 in
the illustrated embodiment, but the tab 224 may be spaced apart
from the edge 208 in other embodiments. The hook surface 222 is
disposed on an opposite side of the tab 224 relative to the ramp
surface 282.
The curved body 204 of the lower shell 190 includes a first
shoulder 292 at the first edge 236 and a second shoulder 294 at the
second edge 238. The shoulders 292, 294 are generally planar
surfaces that extend inward from the respective edges 236, 238. The
strap 248 of the lower shell 190 is disposed proximate to the first
shoulder 292 and extends beyond the first shoulder 292. The catch
284 of the lower shell 190 is disposed along a planar region 286 of
the outer surface 246 proximate to the second shoulder 294.
In the illustrated embodiment, the lower shell 190 is identical to
the upper shell 188. For example, the lower shell 190 shown in FIG.
5 would align with the upper shell 188 if the lower shell 190 is
rotated 180 degrees clockwise (or counterclockwise). Thus, the
latching features of the lower shell 190 have identical shapes as
the latching features of the upper shell 188, and will not be
described in detail herein. For example, the strap 248 may be
identical to the strap 218, and the catch 284 may be a hook surface
of a tab 296 that is identical to the tab 224.
To couple the upper and lower shells 188, 190, the shells 188, 190
are moved towards one another along a coupling axis 298. The distal
end 302 of the strap 218 of the upper shell 188 moves along and/or
parallel to the planar region 286 of the lower shell 190 and
engages a ramp surface 300 of the tab 296. The strap 218 slides
along the tab 296 and deflects radially outward from the natural
resting position of the strap 218 shown in FIG. 5. The distal end
302 slides along the tab 296 until the latching surface 220 clears
the hook surface 284 of the tab 296. After the latching surface 220
clears the hook surface 284, the tab 296 is allowed to resiliently
move radially inward towards the natural resting position of the
strap 218. Meanwhile, the distal end 252 of the strap 248 engages
the ramp surface 282 of the tab 224 and deflects around the tab 224
in the same way as the strap 218 engages and deflects around the
tab 296.
FIG. 6 is an assembled cross-sectional view of the cavity insert
138 and the outer contact 136 taken along the line 5-5. In the
assembled state, the first edge 206 of the upper shell 188 aligns
with the second edge 238 of the lower shell 190, and the latching
surface 220 of the strap 218 engages the hook surface 284 of the
tab 296. Furthermore, the second edge 208 of the upper shell 188
aligns with the first edge 236 of the lower shell 190, and the
latching surface 250 of the strap 248 engages the hook surface 222
of the tab 224. Optionally, there may be a slight clearance between
the latching surfaces 220, 250 and the corresponding hook surfaces
222, 284. The first shoulder 272 of the upper shell 188 faces and
may engage the second shoulder 294 of the lower shell 190, and the
second shoulder 274 of the upper shell 188 faces and may engage the
first shoulder 292 of the lower shell 190. Optionally, there may be
a slight gap 306 between the shoulders 272, 274 of the upper shell
188 and the corresponding shoulders 294, 292 of the lower shell
190. The interface 194 may be defined between the shoulders 272,
274, 292, 294. For example, the first seam 268 of the interface 194
is defined between the shoulder 272 and the shoulder 294, and the
second seam 270 is defined between the shoulder 274 and the
shoulder 292. The strap 218 extends from the upper shell 188 across
the first seam 268 to engage the tab 296 of the lower shell 190.
The strap 248 extends from the lower shell 190 across the second
seam 270 to engage the tab 224 of the upper shell 188.
As shown in FIG. 6, the outer contact 136 is disposed within the
channel 166 of the cavity insert 138. In an embodiment, the outer
contact 136 may support the assembled state of the cavity insert
138 by providing an interior support on the inner surface 168 of
the cavity insert 138. In the illustrated embodiment, without the
interior support of the outer contact 136, the upper shell 188 may
be able to uncouple from the lower shell 190 by sliding the upper
shell 188 in one direction 310 and the lower shell 190 in an
opposite direction 312. Thus, the cavity insert 138 may be
configured such that the cavity insert 138 is able to disassemble
if the outer contact 138 is not within the channel 166 or has a
diameter that is too small relative to the channel 166, to ensure
that the contact assembly 130 (shown in FIG. 2) is assembled
properly.
FIG. 7 is a cross-sectional view of a portion of the assembled
cavity insert 138 according to an alternative embodiment. FIG. 7
shows the latching surface 250 of the strap 248 of the lower shell
190 coupled to the catch 222 of the upper shell 188. However,
instead of the catch 222 being a hook surface of a tab the projects
outward from the outer surface 216, the catch 222 in the
illustrated embodiment is a wall of a recess 316 that is defined
along the outer surface 216. The wall 222 extends inward towards
the channel 166 (shown in FIG. 6) from the outer surface 216. The
latching surface 250 of the strap 248 in the illustrated embodiment
is a hook surface of a tab 318 that protrudes from an inner side
320 of the strap 248. The hook surface faces generally towards a
fixed end 322 of the strap 248 and/or the first edge 236 of the
lower shell 190. The tab 318 extends into the recess 316 when the
upper and lower shells 188, 190 are coupled.
It is to be understood that the above description is intended to be
illustrative, and not restrictive. For example, the above-described
embodiments (and/or aspects thereof) may be used in combination
with each other. In addition, many modifications may be made to
adapt a particular situation or material to the teachings of the
invention without departing from its scope. Dimensions, types of
materials, orientations of the various components, and the number
and positions of the various components described herein are
intended to define parameters of certain embodiments, and are by no
means limiting and are merely exemplary embodiments. Many other
embodiments and modifications within the spirit and scope of the
claims will be apparent to those of skill in the art upon reviewing
the above description. The scope of the invention should,
therefore, be determined with reference to the appended claims,
along with the full scope of equivalents to which such claims are
entitled. In the appended claims, the terms "including" and "in
which" are used as the plain-English equivalents of the respective
terms "comprising" and "wherein." Moreover, in the following
claims, the terms "first," "second," and "third," etc. are used
merely as labels, and are not intended to impose numerical
requirements on their objects. Further, the limitations of the
following claims are not written in means-plus-function format and
are not intended to be interpreted based on 35 U.S.C. .sctn.112(f),
unless and until such claim limitations expressly use the phrase
"means for" followed by a statement of function void of further
structure.
* * * * *